JPS63179727A - Molding method for inner lining of corrugated fiberboard - Google Patents

Abstract

PURPOSE:To absorb looseness of a skin material generated by stress in the contracting direction inside the skin material after molding, eliminate creases and folds on the skin material and keep decorative and touching properties without increasing the cost of the skin material by composing the skin material of a material of high expandability and molding skin material with pulling force applied on. CONSTITUTION:A skin material 9 is composed of a cloth of high fiber expandability such as, for instance, spandex, knit or the like. The whole of the skin material 9 is expanded by pulling the material in the direction that, for instance, recessed sections 19 and projected sections 21 of an inner core 11 continues and applying pulling force on at the time of molding, and compressively pressed simultaneously between a bottom force and a top force of a hot press molding machine and hot pressed. By said process, is shown in the scale-up drawing of section A, stress to contract the portion expanded between the projected sections 21, 21 of the inner core 11 is applied on the skin material 9 after molding. Accordingly, the looseness of the skin material 9 inside the curve of a shaped ceiling 1 at the time of molding can be absorbed by the contraction of the skin material 9 itself between the projected sections 21, 21.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for forming a corrugated cardboard lining used for, for example, automobile door trims, finishes, parcel shelves, molded ceilings, partition panels for trunk rooms, and the like.

[Prior Art] Conventionally, corrugated cardboard lining has been researched and developed as a material in which the corrugated cardboard foot material and the skin material are directly bonded together, and it is lightweight and has an excellent appearance.

Examples of such corrugated cardboard linings include those shown in Figures 4 and 5, which are applied to molded ceilings.
-581@There is a description in the publication).

In FIGS. 4 and 5, a molded ceiling 103 as an inner lining of a roof panel 101 is made up of a skin material 107 adhered to one side of a corrugated cardboard base material 105 on the inside side of the vehicle with an adhesive 109. The corrugated cardboard base material 105 has a flat liner sheet 113 adhered to the upper surface of a corrugated core 111, and the -5 skin material 107 is made of a flat plate-like synthetic resin or the like.

Such a molded ceiling 103 has a corrugated cardboard base material 105 and a skin material 107 simultaneously hot press-molded, and has a similar shape to the roof panel 101.

That is, the molded ceiling 103 is formed in a concave curved shape with a small radius of curvature at both ends in the interior direction and a large radius of curvature at the center when viewed from inside the vehicle interior.

The molded ceiling 103 is an accessory and is attached to the inside of the roof panel 101 by pressing the peripheral portion.

[Problems to be Solved by the Invention] By the way, in such a conventional method of forming a corrugated cardboard lining, the corrugated core 111 and the flat skin material 1 are
07 and liner sheet 113 are simultaneously hot press molded.

For this reason, the surface of the skin material 107 on the inside of the bend may become loose and wrinkles may occur along the wave shape of the core 111, and the skin material 107 may become loose, especially at both ends in the interior direction where the radius of curvature is small. As shown by the arrow in the figure, there is a risk that the core material 111 will break into the recess 111a (see FIG. 6, which is an enlarged view of section a in FIG. 5). There is a problem that decorativeness and tactility are reduced.

Further, since the molded ceiling 103 is attached by pressing the periphery, there is a possibility that the surface of the skin material 107 may become loose, wrinkled, or bent due to variations in the shape of the molded ceiling 103 itself or variations in the precision of the vehicle body.

On the other hand, if the skin material 107 is made of IM with long piles used in luxury cars etc., wrinkles, folds, etc. will be covered by the piles and will not be noticeable, but this will be disadvantageous in reducing the cost of the skin material 107.

This invention has been made in view of the above-mentioned problems, and provides a method for forming a corrugated cardboard lining that can suppress the occurrence of wrinkles and folds during molding and installation without significantly increasing the cost of the skin material. With the goal.

[Means for Solving the Problems] In order to achieve the above-mentioned object, the present invention adheres a fiber-based liner sheet to one surface of a fiber-based core, and adheres a fiber-based liner sheet to the other surface of the fiber-based core. This is a method for forming a corrugated cardboard lining made by adhering a skin material to a board, in which the skin material is made of a highly extensible material, and the navigation skin material is molded under a tensile force.

[Function] In the above configuration, when the corrugated cardboard lining is molded with a tensile force applied to the skin material, the skin material stretches because it is made of a material with high extensibility.

After molding, stress in the direction of contraction acts inside the skin material, and the slack of the skin material due to the elongation is absorbed.

[Examples] Examples of the present invention will be described in detail below based on the drawings.

! ! 1 and 2 show a method of forming a corrugated cardboard lining according to an embodiment in which the present invention is applied to a formed ceiling. Here, FIG. 1 is a structural sectional view of FIG. 2, and FIG. 2 is a partially cutaway perspective view of the molded ceiling.

In FIGS. 1 and 2, a molded ceiling 1 is used as an inner lining of a roof panel 3, and a roof t-side rail 5 is arranged in line with repair parts such as a sun visor, a room mirror, an assist grip, a room lamp, or a roof console (not shown). It is held in place by attachment at the ends of etc.

The molded ceiling 1 is made up of a corrugated cardboard base material 7 and a skin material 9. The corrugated board base material 7 is made by adhering a liner sheet 15 mainly made of fibers to one side of a core 11 mainly made of fibers using a hot-melt sheet 13, and the other side of the core 11 (inner hot melt sheet 17 on the inner surface)
The skin material 9 is adhered by.

The core 11 has a wave shape in which a concave portion 19 and a convex portion 21 are continuous in the inside direction of the vehicle, and the liner sheet 15 and the skin material 9 have a flat plate shape. On the other hand, the skin material 9 is made of, for example, spandex or leek. It is made of a fabric with high stretchability.

For example, manufacturing and molding of such a corrugated cardboard lining is performed as follows.

First, the surface of the corrugated cardboard base material 7 on the side to which the liner sheet 15 has been adhered in advance is placed on the lower die of a hot press molding machine (not shown). Next, the skin material 9 is placed on the convex portion 21 of the core 11 exposed on the other surface of the corrugated board base material 7 with the hot melt sheet 13 interposed therebetween. Then, by pulling the skin material 9, for example, in the direction in which the concave portions 19 and the convex portions 21 of the core 11 are continuous (in the direction of the arrow in FIG. 1), a tensile force is applied during molding to cause the skin material 9 to elongate as a whole, and hot press molding is performed. Heat press by simultaneously pressing between the lower mold and upper mold of the machine.

By applying tensile stress to the skin material 9 during molding in this way, as shown in FIG. 3, which is an enlarged view of section A in FIG.
After molding, stress acts on the outer skin 4A9 to cause it to contract by the amount of elongation between the convex portions 21 and 21 of the core 11 (indicated by the broken line arrow in the figure). Therefore, when the skin material 9 on the inside of the curve of the molded ceiling 1 loosens during molding, the skin material 9 itself prevents the convex portion 21 from loosening.
．． It can be absorbed by shrinking with 2117Sl. As a result, it is possible to prevent wrinkles from forming on the skin material 9 or from bending the skin material 9, especially at the end portion in the direction of the inside of the vehicle.
It is possible to prevent the decorativeness and tactility of the skin material 9 from being impaired without constructing it with 41 meters of expensive long hair.

In addition, the surface of the skin material 9 may loosen during molding due to variations in the shape of the corrugated cardboard base material 7 or the skin material 9, or during installation of the molded ceiling 1 due to variations in the thickness of the room panel 3 or roof site rail 5 as a vehicle body. It is possible to suppress the appearance of wrinkles and creases.

Note that the present invention is not limited to the above embodiments, and for example, the direction in which the skin material 9 is pulled during molding may be two directions: the direction in which the unevenness of the core 11 continues, and the direction in which the unevenness is formed. It is desirable to apply tensile stress at least in the direction in which the unevenness continues. In this case, the same effect can be obtained even with a fabric using l[, such as spandex, only in the direction in which the unevenness of the core 11 is continuous.

Further, in this embodiment, tensile force was applied to the skin material 9 during molding, but tensile force may be applied in advance before molding. That is, even if, for example, the manufacturing and molding of the molded ceiling 1 are carried out separately and a tensile force is applied at the stage of adhering the skin material 9 to the inner part 811, the same effect as in the above embodiment can be obtained.

Further, the bonding between the inner layer 811 and the liner sheet 15 or the skin material 9 may be performed with a normal adhesive instead of the hot melt sheet 13, and the skin material 9 may be made of a non-woven fabric.
It goes without saying that the shape of the core 11 may be arbitrarily set or that a heat insulating material or the like may be inserted on the back surface of the skin material 9 to make it thick.

Furthermore, during molding, for example, by setting the temperature of the lower mold to 150 to 200°C, which is the molding temperature of the corrugated board base material 7, and the temperature of the upper mold to about 100°C, which is below the melt R temperature of the skin material 9, It is possible to prevent the skin material 9 from melting during molding with a simple work process.

Furthermore, the present invention is not limited to the molded ceiling 1, and similar effects can be obtained even when applied to a door finish, a Basel chef, etc.

[Effect of the invention 1 As explained above, according to the present invention, the skin material is made of a highly extensible material and is molded with tensile force applied to the skin material, so that the skin material shrinks inside the skin material after molding. It absorbs the loosening of the skin material due to the stress acting in the direction of the surface, suppresses wrinkles and creases in the skin material, and prevents the decorativeness and feel of the skin material from being impaired without significantly increasing the cost of the skin material. can be suppressed.

[Brief explanation of the drawing]

FIG. 1 is a structural sectional view showing a method of forming a corrugated cardboard lining according to an embodiment of the present invention, FIG. 2 is a partially cutaway perspective view of a molded ceiling as an example to which the present invention is applied, and FIG.
The figure is an action explanatory diagram, and Figure 4 is a structural cross-sectional diagram of a conventional example.
FIG. 5 is a perspective view of a conventional example corresponding to FIG. 2, and FIG. 6 is an explanatory diagram of the operation of the conventional example. 1... Molded ceiling (corrugated cardboard lining) 9... Skin material 11... Core 15... Liner sheet

Claims (1)

[Claims] A method for forming a corrugated cardboard inner lining by adhering a liner sheet mainly made of fibers to one surface of a core mainly made of fibers and adhering a skin material to the other surface, the method comprising: 1. A method for forming a corrugated cardboard lining, characterized in that the lining is made of a material with high extensibility and is formed while a tensile force is applied to the skin material.